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I bought a used 2006 Polaris FST Classic earlier this year, first time out I could smell a real light hint of rubber, almost as if the belt was smoking. Also felt like it was skipping in either the primary or secondary (can't tell). The guy I bought it from had just changed the belt. Anyways, I go to load it on the trailer and could really smell/see smoke from the belt. Brought it in and had it replaced.

Flash forward to today. We just got snow so I decided to take it out again. Every time I tried to go from a start I could smell a little rubber, not bad though. Kept going. I knew the belt was tight enough b/c every once in a while I would hear a squeal. Nothing huge.

So I hit some deep snow and suddenly came to a dead stop with the belt smoking. Clean the area around the sled and got it out. Now when I accelerate all I feel/hear is the belt slipping.

So what is going on, is this common? What should I look for? I sure can't afford new belts every time out!

Make sure that the belt is adjusted properly. You should have about 1-1/4" of deflection. On the secondary you can use the adjuster and get the belt about 1/8" above the clutch when its sitting and you'll be close but an actual check would be a good idea. Also, make sure you have the Polaris 3211121 belt. Anything else is no good on this sled. The 098 belt will smoke and bust regularly due to the heat and power. The 121 belt is kevlar impregnated and can handle it. Venting is big on these as well.

AGAIN....... Make sure the clutches are aligned properly and by the book. The FST specs are not the same as the 2 strokes and proper alignment is huge on these.

Thanks Scooter. I would have assumed the shop checked the alignment, but that could be a bad assumption. Is it that easy to hourglass the belt under load...and I shouldn't be smelling a slight odor of rubber every time I take off?